Air Conditioning FOTON - Tunland

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DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-389
AIR CONDITIONING SYSTEM

PRECAUTION
1. Do not handle refrigerant inside enclosed space or nearby open fire.
2. Protective glasses must be worn.
3. Be careful not to have eyes or skin exposed to liquid refrigerant.
If eyes or skin are exposed to liquid refrigerant:
(a) Rinse them with cold water with plenty of water. 04
(b) Apply clean vaseline onto the skin.
(c) Seek medical advice immediately or reach a hospital for professional treatment.
4. Do not heat up a container or have it exposed to open fire.
5. Do not allow a container to drop off or to be subjected to impact.
6. Do not allow the compressor to work if there is not enough refrigerant inside the refrigeration
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system.
Lack of refrigerant inside the air conditioning system may cause inadequate lubrication and
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damage to compressor.
7. Do not open the high pressure manifold valve when the compressor works.
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(a) Open and close the low pressure valve only.
If the high-pressure valve is opened, the refrigerant may back flow and lead to fracture of
the charging cylinder.
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8. Do not add too much refrigerant into the system.

(a) Too much refrigerant might cause the problems such as poor refrigeration performance, poor fuel
economy, and engine superheating etc.
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9. Do not run the compressor when refrigerant is not available.

10 . Ignition switch representation
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Ignition switch (location) Ignition switch representation
LOCK Ignition Switch: OFF.
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ACC Ignition Switch ACC
ON Ignition Switch: ON.
START Start the engine.
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04-390 DIAGNOSTICS - AIR CONDITIONING SYSTEM
BASIC INSPECTION
Steps Inspection contents Measures
Check for refrigerant. Yes No> go to step 2
• Screw off the protective cap of maintenance
1 valve of air condition refrigeration system,
and push the valve core. No? Add refrigerant.
04 Check whether the result is normal?

Check the air condition switch. Yes No> go to step 3
• Turn on the air conditioner
2 • Check in a visual manner whether the air
conditioner operating indicator lamp goes on. No? to Defect Phenomenon Form
Check whether the result is normal?
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Check the magnetic clutch. Yes No> go to step 4

• Check the magnetic clutch for normal engage-
3
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ment. No? to Defect Phenomenon Form
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Check the drive belt. Yes No> go to step 5
4 • Check the drive belt for slippage.
No? to Defect Phenomenon Form
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Check the compressor. Yes No> go to step 6

• Check whether any abnormal sound may be
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heard during operation of the compressor. No? to Defect Phenomenon Form
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Check the condenser. Yes No> go to step 7
• Check whether there is any rubbish lying
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6 between the condenser and radiator. Remove the rubbish or replace the
• Check the condenser fan for normal work. No?
condenser fan
Check the condenser for normal work.
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Check the pipeline and circuits. Yes Go to defect phenomenon form

• check the pipelines and circuits for any bends
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or twists that might cause jamming. No? Lay again the pipeline and circuits
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COMPONENTS DRAWING
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1 Unit air heater 8 Evaporator shell (lower)

2 Core, unit air heater 9 Motor, circulating air door
3 Water pipe guard board, unit air 10 Blower
heater 11 Governing resistor
4 filter element baffle-plate, air 12 Expansion valve
conditioner 13 Motor, cold/warm air door
5 Filter element, air conditioner 14 Motor, mode air door
04 6 Evaporator shell (upper)
7 Evaporator
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DEFECT PHENOMENON FORM

Check the table below to find the cause of the problem. The numbers rank the possibility of the
causes. Check each part in this order and replace the part if necessary.
Defect phenomenon Suspect Area Reference
1. Fuse -
2. Relay - 04
No function of the air Chapter 61. Heating & A/C - evaporator, replace-
3. Air condition magnifier
conditioning system ment
works
Chapter 61. Heating & A/C - A/C compressor, re-
4. A/C compressor
placement
5. Harness -
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1. Fuse -
2. Relay -
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3. Blower switch Chapter 61. Heating & A/C - blower, replacement

Air output control: 4. Governing resistor of blower Chapter 61. Heating & A/C - blower, replacement
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Blower does not work
5. Blower motor Chapter 61. Heating & A/C - blower, replacement
Chapter 61. Heating & A/C - control mechanism,
6. Air conditioner controller
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replacement
7. Harness -
1. Blower switch Chapter 61. Heating & A/C - blower, replacement
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2. Governing resistor of blower Chapter 61. Heating & A/C - blower, replacement
3. Blower motor Chapter 61. Heating & A/C - blower, replacement
Air output control: Air Chapter 61. Heating & A/C - control mechanism,
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exhaust is inadequate 4. Air conditioner controller
replacement
Chapter 61. Heating & A/C - instrument board air
5. Front air outlet
passage, replacement
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6. Harness -
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Defect phenomenon Suspect Area Reference

1. Fuse -
2. Relay -
Chapter 61. Heating & A/C - A/C compressor,
3. A/C compressor
overhaul
Chapter 61. Heating & A/C - control mechanism,
4. Air conditioner controller
04 Refrigerating system: replacement
Failure to refrigerate Chapter 61. Heating & A/C - evaporator, replace-
5. Air condition magnifier
ment
6. Refrigerant -
Chapter 61. Heating & A/C - A/C pipeline, replace-
7. Air condition pipeline
ment
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8. Harness -
1. Fuse -
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Failure of servo motor Chapter 61. Heating & A/C - A/C air door motor,
2. Motor, air-conditioner air door
of mode air door replacement
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3. Harness -
1. Fuse -
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Failure of temperature Chapter 61. Heating & A/C - unit air heater, replace-
2.Temperature regulation servo motor
regulation servo motor ment
3. Harness -
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NO FUNCTION OF THE AIR CONDITIONING SYSTEM WORKS

Circuit diagram
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Diagnostic steps
1. Check fuse
(a) Disconnect battery negative cable.
(b) Check the fuse inside the fuse box of engine compartment:
• F2（60A）
04 (c) Check the fuse inside the vehicle-body fuse box:
• F7（7.5A）
• F33（5A）
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2. Check harness and connectors (vehicle-body fuse F7- air conditioner controller)
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(b) Disconnect connector C021 of air-conditioner controller.

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(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
F7（7.5A）—C021（A1）＜2Ω
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Yes> go to step 3
No > Maintenance or replace harness.
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3. Check harness and connectors (vehicle-body fuse F33- air conditioner controller)

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the following form.
F33（5A）—C021（A1）＜2Ω
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Yes> go to step 10
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4. Check the harness and connectors (air conditioner controller -ground)

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the following form.
C021 (A14) - ground
＜2Ω
C021 (A16) - ground 04
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Yes > Replace the air conditioner controller, and verify again whether the failure exists.
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BLOWER DOES NOT WORK

Circuit diagram
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Diagnostic steps
1. Check fuse
• F11（60A）
(c) Check the fuse inside the vehicle-body fuse box: 04
• F33（5A）
• F44（30）
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Yes> go to step 2
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No> replace fuse
2. Check the starter relay

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(b) Unplug the relay R4 of starter.
(c) Check the relay R4 of no-load starter.

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Standard resistance:
Multimeter connec-
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Conditions Specified value
tion stitch
Normal situation 1-2 Breakover
Apply power supply
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voltage to position
3-4 ＜2Ω
between stitch 3 and
4,
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Yes> go to step 3
No > Replace the starter relay, and verify again whether the failure exists.
3. Check the blower relay
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(b) Unplug the blower relay R3.
(c) Check the blower relay R3.

Multimeter connec-
tion stitch
04
Normal situation 85–86 Breakover
Apply power supply
voltage to position
30–87 ＜2Ω
between stitch 85
and 86,
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Yes> go to step 4
No > Replace the blower relay, and verify again whether the failure exists.
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4. Check the harness and connectors (blower relay – blower motor)

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(b) Disconnect the connector C025 of blower.

(c) Unplug the blower relay R3.
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(d) Measure the electrical resistance based on the value in

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the following form.

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R3（30）—C025（1）＜2Ω
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Yes> go to step 5
5. Check the harness and connectors (blower motor – blower switch)

(b) Disconnect the connector C018 of blower switch. 04

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(c) Disconnect the connector C025 of front blower.

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the following form.
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C025（2）—C018（1）＜2Ω
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Yes> go to step 6
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6. Check the blower motor

(a) Connect the battery positive terminal (+) to pin 2 of blower
motor connectors.
(b) Connect the battery negative terminal (-) to pin 1 of blower
motor connectors.
04
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Yes> go to step 7
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No > Replace the blower motor, and verify again whether the failure exists.
7. Check the harness and connectors (blower switch - ground)

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(b) Disconnect the connector C018 of blower switch.

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the following form.
C018 (3) - ground ＜2Ω
04
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Yes> go to step 6
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8. Check the harness and connectors (blower switch - air conditioner controller)
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(c) Disconnect the connector C021 of front air conditioner

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controller.
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the following form.
C018（2）—C021（A5）
＜2Ω
04 C018（2）—R3（85）
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Yes > Replace the blower switch, and verify again whether the failure exists.
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AIR OUTPUT CONTROL: AIR EXHAUST IS INADEQUATE

Circuit diagram
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Diagnostic steps
1. Check the governing resistor of blower

(b) Replace the governing resistor of blower.
Yes> go to step 2
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No > Replace the blower governing resistor, and verify again whether the failure exists.
2. Check the harness and connectors (blower motor – blower governing resistor)
(b) Disconnect the connector C024 of blower governing

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resistor.
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(c) Disconnect the connector C025 of blower motor.
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the following form.
C025（2）—C024（4）＜2Ω
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Yes> go to step 3
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3. Check the harness and connectors (blower switch - ground)

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the following form.
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C018 (3) - ground ＜2Ω
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Yes> go to step 4
4. Check the harness and connectors (blower governing resistor – blower switch)
04 (b) Disconnect the connector C018 of blower switch.
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(c) Disconnect the connector C024 of blower governing

resistor.
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the following form.
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C024（1）—C018（6）
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C024（2）—C018（5）＜2Ω
C024（3）—C018（4）

Yes> go to step 5
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5. Check the harness and connectors (blower switch - air conditioner controller)
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(c) Disconnect the connector C021 of front air conditioner

controller.
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the following form.
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C018（2）—C021（A5）＜2Ω
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Yes > Replace the blower switch, and verify again whether the failure exists.
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REFRIGERATING SYSTEM: FAILURE TO REFRIGERATE (GASOLINE)

Circuit diagram
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Diagnostic steps
1. Check fuse
• F20（7.5A）
(c) Check the fuse inside the vehicle-body fuse box: 04
• F25（7.5A）
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Yes> go to step 2
No> replace fuse
2. Check the relay of air conditioner compressor

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(b) Unplug the relay R14 of air conditioner compressor
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(c) Check the relay of air conditioner compressor
Multimeter connec-
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tion stitch
Apply power supply
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voltage to position
3-5 ＜2Ω
5,
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Yes> go to step 3
No > Replace the relay of air conditioner compressor, and verify again whether the failure exists.
3. Check the harness and connectors (relay of air conditioner compressor - ground)
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(b) Unplug the relay of air conditioner compressor
(c) Connect battery negative cable.
(d) Start the engine.
(e) Turn on the A/C switch.
(f) Measure the voltage based on the value in the following

04 form.
Standard voltage
R14 (2) - ground
Battery voltage
R14 (3) - ground
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Yes> go to step 4
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4. Check the harness and connectors (air conditioner controller -air-condition pressure switch)
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(b) Disconnect the connector C021 of air conditioner controller.

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(c) Disconnect the connector A001 of air-condition pressure

switch.
04

the following form.
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C021（A8）—A001（1）＜2Ω
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Yes> go to step 5
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5. Check the harness and connectors (air-condition pressure switch - ground)


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switch.
04

the following form.
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A001 (2) - ground ＜2Ω
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Yes> go to step 6
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6. Check the harness and connectors (air conditioner controller - engine control unit)
(b) Disconnect the connector A001 of air-condition pressure

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switch.
(c) Unplug the electronic control unit E006 of engine.
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the following form.
A001（3）—E006（26）
＜2Ω
A001（4）—E006（50） 04
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Yes > Replace the air-condition pressure switch, and verify again whether the failure exists.
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7. Check the harness and connectors (relay of air conditioner compressor - magnetic clutch)
(a) Unplug the relay R14 of air conditioner compressor
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(b) Unplug the connector E017 of magnetic clutch.

the following form.
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R14（5）- E017 ＜2Ω
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Yes > Replace the magnetic clutch, and verify again whether the failure exists.
8. Check the harness and connectors (replay of air conditioner compressor - engine control unit)
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the following form.
R14（1）—E006（10）＜2Ω
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Yes > Replace the engine control unit, and verify again whether the failure exists.
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REFRIGERATING SYSTEM: FAILURE TO REFRIGERATE (DIESEL

OIL)
Circuit diagram
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Diagnostic steps
1. Check fuse
• F20（7.5A）
04 (c) Check the fuse inside the vehicle-body fuse box:
• F33（5A）
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Yes> go to step 2
No> replace fuse
2. Check the starter relay

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(c) Check the relay, starter.
Multimeter connec-
ee
tion stitch
Apply power supply
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voltage to position
3-5 ＜2Ω
5,
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Yes> go to step 3
No > Replace the starter relay, and verify again whether the failure exists.
3. Check the harness and connectors (starter relay - ground)
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(f) Measure the voltage based on the value in the following

form. 04
Standard voltage
R14 (2) - ground
Battery voltage
R14 (3) - ground
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Yes> go to step 4
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4. Check the relay of air conditioner compressor

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(c) Check the relay of air conditioner compressor

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Multimeter connec-
tion stitch
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Apply power supply

voltage to position
3-5 ＜2Ω
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5,

Yes> go to step 5
No > Replace the relay of air conditioner compressor, and verify again whether the failure exists.
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5. Check the harness and connectors (relay of air conditioner compressor - ground)
04 (f) Measure the voltage based on the value in the following

form.
Standard voltage
R14 (2) - Ground
Battery voltage
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R14 (3) - Ground
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Yes> go to step 6
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6. Check the harness and connectors (air conditioner controller -air-condition pressure switch)
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switch.
04

the following form.
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C021（A8）—A001（1）＜2Ω
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Yes> go to step 7
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7. Check the harness and connectors (air-conditioner pressure switch - engine control unit)

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switch.
(c) Unplug the control unit E006 of engine.
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the following form.
A001（2）—E006（29）＜2Ω
04
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Yes> go to step 8
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8. Check the harness and connectors (air conditioner controller - engine control unit)
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switch.
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the following form.
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A001（3）—E006（11）
＜2Ω
A001（4）—E006（27）
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Yes > Replace the air-condition pressure switch, and verify again whether the failure exists.
9. Check the harness and connectors (relay of air conditioner compressor - magnetic clutch)
(a) Unplug the relay R14 of air conditioner compressor
(b) Unplug the connector E017 of magnetic clutch.
04
the following form.
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R14（5）- E017 ＜2Ω

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Yes > Replace the magnetic clutch, and verify again whether the failure exists.
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10 . Check the harness and connectors (replay of air conditioner compressor - engine control unit)
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the following form.
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R14（1）—E006（48）＜2Ω
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Yes > Replace the engine control unit, and verify again whether the failure exists.
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FAILURE OF SERVO MOTOR OF MODE AIR DOOR

Circuit diagram
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Diagnostic steps
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1. Check fuse
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(b) Check the fuse inside the vehicle-body fuse box:

• F7（7.5A）
• F9（5A）
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• F33（5A）
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Yes> go to step 2
No> replace fuse
2. Check the harness and connectors (air condition controller - mode air door servo motor)
(b) Disconnect the controller connector C022 of air conditioner.

04
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(c) Disconnect the connector C014 of mode air door servo

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motor.
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the following form.
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C022（B2）—C014（1）
C022（B12）—C014（2）
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C022（B1）—C014（3）＜2Ω
C022（B7）—C014（5）
C022（B8）—C014（6）
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Yes> go to step 3
3. Check the mode air door servo motor.

(a) Connect the battery positive terminal (+) to pin 3 of
connector of mode air door servo motor. 04
(b) Connect the battery negative terminal (-) to pin 1 of
connector of mode air door servo motor.
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Yes > Replace the air conditioner controller.
No > Replace the mode air door servo motor, and verify again whether the failure exists.
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FAILURE OF TEMPERATURE REGULATION SERVO MOTOR

Circuit diagram
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Diagnostic steps
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1. Check fuse
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(b) Check the fuse inside the vehicle-body fuse box:

• F7（7.5A）
• F9（5A）
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• F33（5A）
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Yes> go to step 2
No> replace fuse
2. Check the harness and connectors (air condition controller - temperature regulation servo motor)
(b) Disconnect the controller connector C022 of air conditioner.

04
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(c) Disconnect the temperature regulation servo motor C031.

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the following form.
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C022（B2）—C031（1）
C022（B11）—C031（2）
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C022（B1）—C031（3）＜2Ω
C022（B5）—C031（5）
C022（B6）—C031（6）
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Yes> go to step 3
3. Check the temperature regulation servo motor

(a) Connect the battery positive terminal (+) to pin 3 of
04 connector of temperature regulation servo motor.
(b) Connect the battery negative terminal (-) to pin 1 of
connector of temperature regulation servo motor.
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Yes > Replace the air conditioner controller.
No > Replace the temperature regulation servo motor, and verify again whether the failure exists.
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Air Conditioning FOTON - Tunland

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DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-389

AIR CONDITIONING SYSTEM

8. Do not add too much refrigerant into the system.

9. Do not run the compressor when refrigerant is not available.

04-390 DIAGNOSTICS - AIR CONDITIONING SYSTEM

04 Check whether the result is normal?

Check the magnetic clutch. Yes No> go to step 4

Check the compressor. Yes No> go to step 6

Check whether the result is normal?

Check the pipeline and circuits. Yes Go to defect phenomenon form

DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-391

04-392 DIAGNOSTICS - AIR CONDITIONING SYSTEM

1 Unit air heater 8 Evaporator shell (lower)

DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-393

DEFECT PHENOMENON FORM

3. Blower switch Chapter 61. Heating & A/C - blower, replacement

04-394 DIAGNOSTICS - AIR CONDITIONING SYSTEM

Defect phenomenon Suspect Area Reference

DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-395

NO FUNCTION OF THE AIR CONDITIONING SYSTEM WORKS

04-396 DIAGNOSTICS - AIR CONDITIONING SYSTEM

(b) Disconnect connector C021 of air-conditioner controller.

DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-397

(c) Measure the electrical resistance based on the value in

Check whether the result is normal?

(b) Disconnect connector C021 of air-conditioner controller.

04-398 DIAGNOSTICS - AIR CONDITIONING SYSTEM

(c) Measure the electrical resistance based on the value in

Check whether the result is normal?

(b) Disconnect connector C021 of air-conditioner controller.

DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-399

(c) Measure the electrical resistance based on the value in

Check whether the result is normal?

04-400 DIAGNOSTICS - AIR CONDITIONING SYSTEM

BLOWER DOES NOT WORK

DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-401

Check whether the result is normal?

No> replace fuse

2. Check the starter relay

(a) Disconnect battery negative cable.

(c) Check the relay R4 of no-load starter.

Check whether the result is normal?

3. Check the blower relay

04-402 DIAGNOSTICS - AIR CONDITIONING SYSTEM

(a) Disconnect battery negative cable.

(c) Check the blower relay R3.

Check whether the result is normal?

4. Check the harness and connectors (blower relay – blower motor)

(b) Disconnect the connector C025 of blower.

(d) Measure the electrical resistance based on the value in

the following form.

DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-403

Check whether the result is normal?

5. Check the harness and connectors (blower motor – blower switch)

(b) Disconnect the connector C018 of blower switch. 04

(c) Disconnect the connector C025 of front blower.

(d) Measure the electrical resistance based on the value in

Multimeter connection Standard value

Check whether the result is normal?

04-404 DIAGNOSTICS - AIR CONDITIONING SYSTEM

No > Maintenance or replace harness.